Devices and Methods for Installing Ductwork Components

ABSTRACT

The present invention relates to methods and devices for installation of a component or device such as an air purification system onto the ductwork of a heating and/or cooling system.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This Application claims priority to U.S. Provisional Patent Application Ser. No. 60/697,395, filed Jul. 7, 2005, and claims the priority thereof, the subject matter of which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to heating and cooling ductwork, and more particularly to devices and methods for installing add on components to an existing heating and/or cooling system.

BACKGROUND OF THE INVENTION

In-furnace filters can trap germs, molds, fungi, bacteria and other air borne particles in the air circulating through a heating and/or cooling system. These particles can multiply and spread throughout a home via air circulating through the furnace filters and cause adverse health affects to exposed individuals.

Standalone room air filters and purifiers have been developed to reduce the concentration of air particles such as mold, fungi and bacteria. However, these standalone devices generally only clean the air in a small area, while allowing the continual flow of contaminated air through other rooms and even into the room containing the standalone device.

Ultraviolet air purification systems, such as the BREATHECLEAN® home air purification system, have been developed to continually clean the air circulating through a heating and/or cooling system. Such air purification devices can be installed into existing heating and/or cooling ductwork and can facilitate continual purification of air flowing through the heating and/or cooling system.

There is a need in the art for methods and devices for installing devices into existing ductwork.

BRIEF SUMMARY OF THE INVENTION

The present invention, in one embodiment, is an installation kit having a template component and a mounting component. The template component has at least one drill guide defined by the template component and an adhesive component associated with one side of the template component. The mounting component is configured to be positioned adjacent to the template component and has at least one hole defined by the mounting component and at least one projection associated with the mounting component.

The present invention, in another embodiment, is a method of attaching a device to ductwork of a heating or cooling system. The method includes attaching a template component to the ductwork, attaching a mounting component to the template component, and mounting the device onto the mounting component.

While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an installation template being applied to an outside surface of ductwork, according to one embodiment of the present invention.

FIG. 2 depicts a screw hole being created through the installation template and ductwork, according to one embodiment of the present invention.

FIG. 3 depicts a light hole being drilled through the installation template and ductwork, according to one embodiment of the present invention.

FIG. 4 depicts a mounting plate being attached to the ductwork such that the holes drilled into the installation template align with the openings of the mounting plate, according to one embodiment of the present invention.

FIG. 5 depicts the mounting plate being secured to the ductwork, according to one embodiment of the present invention.

FIG. 6 depicts the ultraviolet light bulbs of an air purification system being inserted though the light openings of the mounting plate into the interior space of the ductwork, according to one embodiment of the present invention.

FIG. 7 depicts an ultraviolet air purification system mounted to the ductwork, according to one embodiment of the present invention.

FIG. 8 is a perspective view of a BREATHECLEAN® air purification system, according to one embodiment of the present invention.

DETAILED DESCRIPTION

The invention relates to devices and methods for installing a device such as an air purification system onto/into existing ductwork of a heating and/or cooling system. In one aspect, the invention relates to installation kits including an installation template, a mounting plate, and, according to one embodiment, an air purification system. In some embodiments, the kit can further include appropriate drill bits and/or hole saws, warning labels, gloves to handle the air purification system, a warranty card, and a maintenance sticker. In another aspect, the invention pertains to a method of installing an air purification system into existing ductwork, the method including the step of applying an installation template to an outside surface of a heating and/or cooling duct. The method can further include the step of operably coupling a mounting plate to the installation template and operably coupling an air purification device to the mounting plate.

As described above, the kit of the present invention can include an installation template that facilitates drilling appropriate holes into the surface of existing ductwork. As depicted in FIGS. 1-3, installation template 100 can have a generally rectangular shape and can include drill guides on one surface of the template and an adhesive on the opposite surface of the template. In general, the drill guide portions of installation template 100 provide the user with guides for drilling appropriate holes into the surface of ductwork 10. In one aspect of the invention, each guide is a hole formed in the template at an appropriate location for forming the appropriate hole in the ductwork. In one embodiment, installation template 100 can include fastener holes guides 102 positioned around the periphery of template 100, which facilitate drilling appropriate fastener holes into ductwork 10. In certain embodiments, installation template 100 can include 4-8 fastener hole guides 102. In a further alternative, the installation template 100 can include any appropriate number of fastener hole guides in any configuration.

The installation template 100 can also include light bulb guides 106, which facilitate drilling appropriate holes into ductwork 10 for inserting the ultraviolet light bulbs of an air purification system into the interior portion of ductwork 10. One of ordinary skill in the art will recognize that the size, number, and spacing of light hole guides can be guided by the size, number, and spacing of the ultraviolet light bulbs employed in a particular air purification system. Although FIGS. 1-3 depict installation template 100 attached to ductwork 10 in a horizontal orientation, alternative embodiments allow for the template 100 to be attached to ductwork in any orientation. Further, according to another embodiment, the template 100 can have any known shape that may be useful to ensure attachment of a mounting plate and air purification system as discussed herein.

The kits of the present disclosure can also include a mounting plate, which facilitates mounting an air purification system to a heating and/or cooling system. In one embodiment, as depicted in FIGS. 4 and 5, mounting plate 200 can have a generally rectangular shape and can define a plurality of fastener holes 202 positioned around the periphery of mounting plate 200. In some embodiments, mounting plate can include 4-8 fastener holes 202. Alternatively, the plate 200 can have any known number of holes 202 that may be helpful in allowing for attachment of the plate to the duct work and further for attachment of the air purification device to the ductwork. Fastener holes 202 facilitate operably coupling mounting plate 200 to ductwork 10 by an appropriate fasteners such as, for example, screws, pins and the like.

Mounting plate 200 can also define one or more bulb openings 204, which facilitate introducing the ultraviolet light bulb portions of an air purification device into the interior of a heating and/or cooling ductwork. According to one embodiment, the bulb openings 204 have a diameter of about 2¼ inches. Alternatively, the openings can be any diameter necessary or useful for receiving any light bulbs or other components associated with the device to be attached to the ductwork. In one aspect of the invention, the openings 204 are 2 3/16 inches apart. Alternatively, the space between the openings can be any distance appropriate for any configuration of openings 204 on the plate 200. In some embodiments, mounting plate 200 can include two bulb openings, while in other embodiments mounting plate 200 can include one, three or four bulb openings. Mounting plate 200 can have the same size and shape as installation template 100. Additionally, the openings 202, 204 defined by mounting plate 200 can be designed to align with the holes cut into installation template 100. FIG. 6 depicts light bulb 210 of a BREATHECLEAN® air purification system positioned within bulb opening 204. As discussed above, the configuration, size, spacing, and number of bulb openings 204 can be any known configuration, size, spacing, or number that would be useful in providing for the attachment of an air purification device or system.

The mounting plate 200 can further include one or more projections 208, including a plurality, that extend from mounting plate 200. Projections 208 are adapted to fit into openings on an air purification system, which facilitates operably coupling an air purification device to mounting plate 200. Once projections 208 have been inserted into openings on an air purification system, the air purification system can be secured to the mounting plate by any appropriate fastener such as, for example, locking collar, nuts, thumb screws or the like. FIGS. 6 and 7 depict a BREATHECLEAN® air purification system being mounted onto mounting plate 200 via projections 208. The projections 208 can be configured in any configuration, size, spacing, or number that would be useful in providing for the attachment of an air purification device or system.

The kit can also include an air purification device such as, for example, a BREATHECLEAN® air purification device. Alternatively, the kit and methods disclosed herein can be used with any known purification device or any other device or component that is intended for attachment to ductwork. As depicted in FIG. 8, BREATHECLEAN® air purification system 300 can include a base portion 302 and a plurality of ultraviolet lights 304 that extend from base 303. In some embodiments, system 300 can include at least two 36 watt ultraviolet light bulbs. Base portion 302 can define a plurality of openings 306 that are adapted to receive protrusions 208 on mounting plate 200. Additionally, base portion 302 can include thumb screws 308 which can lock protrusions 208 into openings 306 to secure system 300 on mounting plate 200.

The kits can further include gloves to handle the ultraviolet light bulb portions of the air purification devices. The oils on a user's hands can create hot spots on the ultraviolet lights and reduce the useful life of the ultraviolet bulbs. The gloves can be formed from any suitable material such as cloth, polymers or combinations thereof. Additionally, the kits can include one or more warning labels that indicate that ultraviolet light bulbs contain mercury. The warning labels can also indicate that a user should avoid direct skin contact with mercury.

In use, the installation template 100 is attached or affixed or otherwise operably coupled to the ductwork of a heating and/or cooling system, then the mounting plate 200 is operably coupled to the ductwork over or adjacent to the installation template 100, and then the device or component such as an air purification device is operably coupled to the mounting plate 200.

In one embodiment, the installation template 100 can be affixed to a heating and/or cooling system by removing the backing from the adhesive side of the template and contacting the adhesive to a desired surface of the ductwork. Alternatively, the template 100 can be attached or otherwise operably coupled to the ductwork by any known attachment method or device.

The holes or openings are then formed in the ductwork using the guides on the template 100. For example, screw holes can be drilled through the fastener guide portions of the installation template and the corresponding portions of the ductwork. In some embodiments, a 3/32″ drill bit can be used to drill the screw holes. A hole saw can then be used to cut holes in the bulb guide portion of the installation template. In some exemplary embodiments, a 2¼″ hole saw can be used to cut two circular openings having a diameter of about 2¼″ through the bulb guide portions of the template and the corresponding portions of the ductwork.

The mounting plate 200 can then be operably coupled to the ductwork, according to one embodiment. In one embodiment, screws, or other appropriate fasteners, can be inserted through the fastener holes of the mounting plate into the fastener holes drilled in the template and ductwork to secure the mounting plate 200 to the ductwork. Alternatively, any appropriate fastener can be used to secure the mounting plate 200 to the ductwork.

In accordance with one aspect of the invention, a device or component can then be operably coupled to the ductwork. For example, according to one embodiment, an air purification system is mounted to the mounting plate by positioning the light bulb portions of the purification system within the bulb openings and positioning the projections on the mounting plate in appropriate openings on the air purification system. The air purification system can be secured to the mounting plate using an appropriate fastener such as a thumb screw. In some embodiments, up to about 16″ of depth inside the ductwork may be necessary to accommodate the length of the ultraviolet light bulbs. In one aspect of the invention, the air purification system can be a BREATHECLEAN® air purification system.

The embodiments above are intended to be illustrative and not limiting. Additional embodiments are within the claims. Although the present invention has been described with reference to particular embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. 

1. An installation kit comprising: (a) a template component comprising: (i) at least one drill guide defined by the template component; and (ii) an adhesive component associated with one side of the template component; and (b) a mounting component configured to be positioned adjacent to the template component, the mounting component comprising: (i) at least one hole defined by the mounting component; and (ii) at least one projection associated with the mounting component.
 2. The kit of claim 1, wherein the at least one drill guide comprises at least one fastener hole guide.
 3. The kit of claim 1, wherein the at least one drill guide comprises at least one light bulb hole guide.
 4. The kit of claim 1, wherein the at least one hole comprises at least one fastener hole.
 5. The kit of claim 1, wherein the at least one hole comprises at least one light bulb hole.
 6. The kit of claim 1, wherein the at least one drill guide defined by the template component and the at least one hole defined by the mounting component are adjacent when the mounting component is positioned adjacent to the template component.
 7. The kit of claim 1, further comprising an air purification device, configured to be positioned adjacent to the mounting component.
 8. The kit of claim 7, wherein the at least one projection is disposed within at least one opening defined by the air purification device.
 9. The kit of claim 7, wherein the air purification device comprises at least one ultraviolet light bulb that is disposed within at least one of the at least one holes defined by the mounting component.
 10. A method of attaching a device to ductwork of a heating or cooling system, the method comprising: attaching a template component to the ductwork; attaching a mounting component to the template component; and mounting the device onto the mounting component.
 11. The method of claim 10, wherein the template component comprises: (a) at least one drill guide defined by the template component; and (b) an adhesive component associated with one side of the template component.
 12. The method of claim 10, wherein the mounting component comprises: (b) at least one hole defined by the mounting component; and (c) at least one projection associated with the mounting component. 